Daewoo Tacuma: Body Repair Manual - part 18

FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER  6–3

1-2. REPAIR PROCEDURE

1. Remove the related parts.

•

Doors.

•

Weather strips, pillar trims and related parts.

•

Carpet.

•

Seat belt assembly

•

Door switch and wiring harness.

•

Fuel pipe and brake oil pipe.

•

Other related parts.

NOTE:  Remove according to part damaged.

2. Pull out and straighten the damaged area to approxi-

mately the original shape.

•

Damage may extend to the inner roof frame, the

inner frame door opening and the floor. Determine
the extent of the damage first, so the frame can
be pulled out properly.

NOTE:  Use heat-resistant protective cover for pro-
tect painting areas, seats, carpets and other parts.

•

Pull out and straighten the damaged areas.

•

Do not pull out more than necessary.

3. Cut and pry off the frame door opening.

•

Check the damage on the frame door opening, then

cut the new frame door opening so it will overlap
by 30mm in the pillar, front and rear.

•

Cut the damaged area with a hand saw along the

bold line as shown.

NOTE:  Be careful not to cut the inner panel. This
could result in extensive repair.

•

If the damage involves part of the center pillar, cut
them as shown.

•

Center punch around the spot weld imprints on the

welded flange.

•

Use the special spot cutter to drill holes at the

spot weld nuggets.

NOTE: When drilling holes be careful not to drill down
to the inner panel.

•

Pry off the frame door opening panel with an air

chisel, leaving the welding flanges intact.

CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.

4. Mold damaged related parts.

•

Fill any holes drilled by welding.

CAUTION:  To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.

•

Use a hammer and dolly to mold damaged areas

of the remaining inner panel and even out the
welding flanges.

•

Level and finish the burrs from the pried off spot

welds with disc sander.

•

Sand off the paint and undercoat from both sides

of the flange to be welded.

Fig. 3

Fig. 2

6–4   FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER

•

Perform a trial welding first, and check the weld-

ing condition.

•

Increase the number of spot by 20% for areas to

be spot welded.

5. Set the new frame door opening.

•

Grind both sides of the welding section of the pre-

pared frame door opening part with a disk sander
to remove the paint and expose the steel plate.

•

Clamp the new panel in place with the vise grips.

•

Tack weld the clamped section for temporary in-

stallation.

CAUTION:  To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.

7. Finish the welding areas.

•

Level the gas or MIG welded areas with a disc

sander, then even out high areas with a hammer
being careful not to deform them.

CAUTION: To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.

•

Use a hammer and dolly to even out the spot

welded flanges for a close fit with the surface of
the frame door opening panel.

•

Fill in deformations and level differences of the

welded areas with solder or putty, then finish.

8. Apply the sealer.

•

Apply the sealer to the matching surfaces of the

floor and frame door opening.

Fig. 4

•

Remove the vise grips and temporarily install the

fender and doors, then check the clearances, level
differences and outer appearance.

6. Perform the main welding.

•

Weld the front, rear frame door opening and cen-

ter pillar at the butt joints with a gas or MIG
welder.

•

Spot weld the frame door opening and center

pillar as shown.

CAUTION:  To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.

Fig. 5

FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER  6–5

 9. Apply the undercoat.

•

Undercoat to the front floor.

10.Apply the paint.

CAUTION

•

Ventilate when spraying paint. Most paint contains

substances that are harmful if inhaled or swal-
lowed.

Read the paint label before opening paint con-

tainer.

•

Avoid contact with skin. Wear an approved res-

pirator, gloves, eye protection and appropriate
clothing when painting.

•

Paint is flammable. Store in a safe place, and

keep it away from sparks, flames or cigarettes.

11.Coating the anti-rust agents.

•

Coating the anti-rust agents to the inside of frame

door opening areas sufficiently.

12.Install the related parts.

•

Clean the passenger compartment.

•

Wiring harness and related parts.

•

Seat belt assembly and carpet.

•

Trims and weather strips.

•

Door and others.

•

Install in the reverse order in which they were re-

moved.

13.Check and adjust.

•

Check clearances and level differences.

•

Check the door locking and unlocking condition.

•

Check for water leaks in the passenger compart-

ment.

Fig. 6

WHOLE AREA OF
SIDE TUNNEL

INSERT THE SPRAY GUN NOZZLE THROUGH

THIS HOLES FOR COATING

6–6   FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER

2. DOOR

2-1. REPAIR PROCEDURE

1. Remove the related parts.

•

Door trim and related parts.

•

Wiring harness and solenoid valve.

•

Glass and window lifter.

•

Linkage, lock set and handle.

•

Others.

NOTE: Inspection and choose the usable parts.

2. Remove the door.

•

Remove the bolt from door check hinge(1) and re-

move the four bolts from door assembly(2).

Fig. 7

•

Check and adjust the clearances and level differ-

ences of doors, fender, pillar, roof and side panel
outers.

•

Check any deformation.

5. Remove the new door.

•

Remove the four bolts from door assembly.

6. Apply the paint.

CAUTION

•

Ventilate when spraying paint. Most paint contains

substances that are harmful if inhaled or swal-
lowed.

Read the paint label before opening paint con-

tainer.

•

Avoid contact with skin. Wear an approved respi-

rator, gloves, eye protection and appropriate cloth-
ing when painting.

•

Paint is flammable. Store in a safe place, and keep

it away from sparks, flames or cigarettes.

8. Coating the anti-rust agents.

•

Coating the anti-rust agents to the inside of bot-

tom areas.

3. Preparation of the new door.

•

Preparation of the new door and check damaged

areas.

4. Preinstall the door.

•

Fix the four bolts.

Fig. 8